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Unread 09-23-2016, 01:03 PM   #31
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Default Re: Power Surging?

Do You have the software and cable to program the controller and disable the HPD setting?

I should have asked You to notice the voltage on the "yellow" wire when the MCOR micro-switch closed.

The only thing that makes sense is that with the resistor in place, the MCOR wiper voltage at the time the micro-switch closed would have been less than now.

Since we know the voltage is close to 0v with the Pedal up, disconnect the 2-pin connector from the MCOR and place a larger paper clip jumping the 2 pins on the harness side.

That way when You turn the key switch ON, the controller will power up with the MCOR throttle signal close to 0v and not the voltage at the time the pedal moves and releases the micro-switch plunger inside the MCOR.
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Unread 09-23-2016, 05:01 PM   #32
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Default Re: Power Surging?

Quote:
Originally Posted by Sergio View Post
Do You have the software and cable to program the controller and disable the HPD setting?

I should have asked You to notice the voltage on the "yellow" wire when the MCOR micro-switch closed.

The only thing that makes sense is that with the resistor in place, the MCOR wiper voltage at the time the micro-switch closed would have been less than now.

Since we know the voltage is close to 0v with the Pedal up, disconnect the 2-pin connector from the MCOR and place a larger paper clip jumping the 2 pins on the harness side.

That way when You turn the key switch ON, the controller will power up with the MCOR throttle signal close to 0v and not the voltage at the time the pedal moves and releases the micro-switch plunger inside the MCOR.
I won't get a chance to work on it tonight, but will resume tomorrow.
Assuming that jumping the 2-pin connector on MCOR makes the cart run, what would be my next step? Replace MCOR? Disable HPD on controller?
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Unread 09-23-2016, 05:02 PM   #33
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Default Re: Power Surging?

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Originally Posted by Ribber View Post
I won't get a chance to work on it tonight, but will resume tomorrow.
Assuming that jumping the 2-pin connector on MCOR makes the cart run, what would be my next step? Replace MCOR? Disable HPD on controller?
Forgot to mention, I do not have software and cable for controller.
I do have a MCOR4 I could try.
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Unread 09-23-2016, 09:46 PM   #34
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Default Re: Power Surging?

If it works, You will need to add a resistor in line with the Green and Black wire by-pass connection You have now.

Based on the information You posted, you need a 3.9kΩ 5% 1/4watt resistor.
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Unread 09-24-2016, 09:42 PM   #35
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Default Re: Power Surging?

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Originally Posted by Sergio View Post
If it works, You will need to add a resistor in line with the Green and Black wire by-pass connection You have now.

Based on the information You posted, you need a 3.9kΩ 5% 1/4watt resistor.
I jumped the 2-pin harness on MCOR with paper clip and the cart ran.
So, I guess I need a resistor in line with black and white wire.
I'm posting a picture of the resistor/splice, but I'm not sure how to wire it.
Where do I get this from and how do I wire it?
I'm quite sure nowhere local has this.
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File Type: jpg 20160924_165747.jpg (190.7 KB, 0 views)
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Unread 09-25-2016, 10:41 AM   #36
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Default Re: Power Surging?

Radio Shack carries the 3.9kΩ 5% 1/2watt resistor.

The 1/2 watt size may be easier for your to solder or crimp.

Instead of having the Green and Black wires connected together as You have now, just put the resistor in line with those 2 wires.

I can give You a link to order on line (Mouser.com, Newark.com, Digikey.com, etc), but You will pay like $9 shipping for a $0.25 part.
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Unread 09-25-2016, 11:01 AM   #37
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Default Re: Power Surging?

Quote:
Originally Posted by Sergio View Post
Radio Shack carries the 3.9kΩ 5% 1/2watt resistor.

The 1/2 watt size may be easier for your to solder or crimp.

Instead of having the Green and Black wires connected together as You have now, just put the resistor in line with those 2 wires.

I can give You a link to order on line (Mouser.com, Newark.com, Digikey.com, etc), but You will pay like $9 shipping for a $0.25 part.
Looks like I have a 5K ohm resistor now. I saw the 1/4 watt 3.9k ohm on Amazon $5.77 free Prime shipping. I assume the 1/2 watt would be ok too?

When I connect the 3.9 resistor in line with black wire (completely eliminating the white wire I assume?), will I have full throttle? I'm scared I will have a 'half speed' scenario like with the old resistor.
Sorry for ignorance, I don't fully understand what different resistors do.
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File Type: jpg 20160924_165747.jpg (190.7 KB, 0 views)
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Unread 09-25-2016, 04:39 PM   #38
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Default Re: Power Surging?

If Amazon has the 1/2 watt version of the 3.9kΩ, it is easier to work with, but 1/4 watt is enough for the little current that goes through the throttle circuit.

All club car 3-wire throttles work on the voltage divider principle, the Potentiometer part of the MCOR just varies the voltage at the wiper from lowest to highest connection point.

Adding the 5.1kΩ resistor at the top as you had on reverse, would lower the maximum voltage at the top of the MCOR to about 4.7v, not enough to trigger full throttle.

It would also proportionally lower the voltage at the wiper when the MCOR moved enough to release the plunger on the MCOR, which causes the controller to power up and check that the throttle input is below the maximum voltage before HPD is activated.

I think the 3.9kΩ should give you about 5.1v-5.6-v at WOT and still keep the pedal at MCOR micro-switch voltage low enough not to trigger the HPD fault.
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Unread 09-25-2016, 08:14 PM   #39
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Default Re: Power Surging?

Quote:
Originally Posted by Sergio View Post
If Amazon has the 1/2 watt version of the 3.9kΩ, it is easier to work with, but 1/4 watt is enough for the little current that goes through the throttle circuit.

All club car 3-wire throttles work on the voltage divider principle, the Potentiometer part of the MCOR just varies the voltage at the wiper from lowest to highest connection point.

Adding the 5.1kΩ resistor at the top as you had on reverse, would lower the maximum voltage at the top of the MCOR to about 4.7v, not enough to trigger full throttle.

It would also proportionally lower the voltage at the wiper when the MCOR moved enough to release the plunger on the MCOR, which causes the controller to power up and check that the throttle input is below the maximum voltage before HPD is activated.

I think the 3.9kΩ should give you about 5.1v-5.6-v at WOT and still keep the pedal at MCOR micro-switch voltage low enough not to trigger the HPD fault.
Ok, I ordered the 1/2 watt resistor and it should be here Tuesday or Wednesday. I'll report back when I get it connected.
Hopefully, all will be good.
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Unread 09-28-2016, 08:39 PM   #40
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Default Re: Power Surging?

Quote:
Originally Posted by Sergio View Post
If Amazon has the 1/2 watt version of the 3.9kΩ, it is easier to work with, but 1/4 watt is enough for the little current that goes through the throttle circuit.

All club car 3-wire throttles work on the voltage divider principle, the Potentiometer part of the MCOR just varies the voltage at the wiper from lowest to highest connection point.

Adding the 5.1kΩ resistor at the top as you had on reverse, would lower the maximum voltage at the top of the MCOR to about 4.7v, not enough to trigger full throttle.

It would also proportionally lower the voltage at the wiper when the MCOR moved enough to release the plunger on the MCOR, which causes the controller to power up and check that the throttle input is below the maximum voltage before HPD is activated.

I think the 3.9kΩ should give you about 5.1v-5.6-v at WOT and still keep the pedal at MCOR micro-switch voltage low enough not to trigger the HPD fault.
Got the new resistor wired inline with the black wire. Didn't GPS it, but it's still not running full throttle. Feels exactly like it did at half speed.
Still was intermittent at pedal, sometimes run, sometimes not. When it would not run, the controller still had 3 red blinks.
The yellow wire from MCOR at controller was 5.3V pedal fully depressed. Ohms were @1100 pedal up and @5400 pedal depressed.
I'm lost and don't know what to do now.
I have a MCOR4 on hand. Should I try it?
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